UV irradiation for surface cleaning

ABSTRACT

There are disclosed methods of controlling the presence of surface and airborne microorganisms in an air handler. The method may comprise: energizing a germicidal lamp to emit distributed UVC radiation; positioning the germicidal lamp in proximity to the heat transfer coil, wherein the intensity of the UVC radiation striking a heat transfer coil of the air handler is to a degree independent of the distance of the germicidal lamp to the heat transfer coil; directing the UVC radiation across the coil face to the coil&#39;s tube and fins; reflecting and directing the ultraviolet by the coil&#39;s tube and the fins-throughout the coil, thereby increasing the flux density of the ultraviolet radiation and the dosage of the radiation applied to airborne microorganisms and microorganisms carried on the surface; continuing to irradiate the surface with the UVC radiation from the germicidal lamp at least intermittently until the surface is organically clean.

RELATED APPLICATION INFORMATION

This application is a continuation of application Ser. No. 10/223,433filed Aug. 19, 2002, which is a division of application Ser. No.09/167,376 filed Oct. 6, 1998, which is a continuation-in-part ofapplication Ser. No. 08/803,350 filed Feb. 20, 1997 now U.S. Pat. No.5,817,276.

This application is related to: (1) application Ser. No. 09/170,361filed Oct. 13, 1998, now U.S. Pat. No. 6,313,470; (2) application Ser.No. 09/172,637 filed Oct. 14, 1998, now U.S. Pat. No. 6,245,293; (3)application Ser. No. 09/173,081 filed Oct. 14, 1998, now U.S. Pat. No.6,267,924; (4) application Ser. No. 09/172,638 filed Oct. 13, 1998 nowU.S. Pat. No. 6,280,686.

NOTICE OF COPYRIGHTS AND TRADE DRESS

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. This patent document may showand/or describe matter which is or may become trade dress of the owner.The copyright and trade dress owner has no objection to the facsimilereproduction by any one of the patent disclosure as it appears in thePatent and Trademark Office patent files or records, but otherwisereserves all copyright and trade dress rights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the reduction of energy usagein cooling and heating systems and more particularly to minimizing airhorsepower and maximizing the operating performance of heat exchangersin cooling and heating systems.

2. Description of Related Art

One mature industry that is economically sensitive to costs is theheating, ventilation and air conditioning (HVAC) industry. Because ofthe competitive nature of both the construction and HVAC industries,HVAC systems must be inexpensive to install. Of a more global interestthough, is the cost to operate and maintain HVAC systems. Often, abuilding owner will replace an aging HVAC system as the reduction inoperating and maintenance costs can offset the retrofit cost, sometimesin a matter of months.

Broad social and energy policies also favor more efficient HVAC systems.In these days of electricity deregulation and conservation, it hasbecome even more important to conserve energy consumption. Recently,entire electrical grids have shut down on very hot days in part becauseof the huge demand of HVAC systems running at extreme capacity.Furthermore, energy conservation translates directly into improvedenvironmental conditions and decreased reliance upon foreign petroleum.

HVAC systems are typically comprised of fans and ductwork for moving airwhere needed. An HVAC system will include a cooling and heating sectionfor, respectively, cooling and heating the air. In most HVAC systems,air is drawn in, filtered, cooled and dehumidified or heated andhumidified, and then delivered to a room. The greatest portion of thisair is drawn from the conditioned space for recirculation through theHVAC system. Considerable effort has been made to make these componentsmore efficient.

One of several recently used methods of saving energy in an HVAC systemincludes the use of variable frequency drives on any motor used in aHVAC system. When and if the system load decreases, this can be sensedand the motors in the HVAC system will be slowed to an equilibrium valueto save motor energy consumption. Another method is to reduce the designamount of outdoor air to eliminate having to condition it. Anothermethod is an economizer cycle that utilizes 100% outdoor air when itsambient temperature is suitable for cooling the space. Another method isto replace aging equipment with newer and more efficient equipment.

One other factor impacting design and operation of HVAC systems isindoor air quality (IAQ). One major factor in IAQ today is the amount ofoutdoor air introduced into an otherwise sealed space serviced by anHVAC system. The HVAC industry has adapted standards for theintroduction of outdoor air into spaces serviced by an otherwise closedHVAC system. These include offices, residential, commercial, industrialand institutional spaces, as well as the interior of vehicles such ascars, buses, planes and ships. In addition to controlling indoor air foroccupant comfort, the goal of HVAC systems is to provide air withreduced levels of particulates, gases and bioaerosols, be it forsemiconductor, pharmaceutical or food processing facilities, hospitals,schools or offices and now the home.

Most ventilation systems today include a cooling section. The coolingsection includes a type of heat exchanger typically referred to as a“cooling coil,” through which air is forced and cooled. This coolingcoil operates thermodynamically to remove both sensible and latent heatfrom the forced air. Cooling coils typically are made using aluminumfins over refrigerant tubes which have been formed into a desired shape.Essentially the same coil arrangement in used in all cooling systems,whether in HVAC systems for occupied spaces, or for refrigerators andfreezers.

A similar configuration is often used in heating sections, though thethermodynamic operation is opposite to that in a cooling section. Theheat exchanger of a heating section often comprises a coil, and water ofan elevated temperature passes through the coil. The heating coil isfashioned in a manner to promote heat transfer from the water to theheating coil. The heating coil is further fashioned to promote heattransfer from the heating coil to air which is forced across and throughthe heating coil.

As a normal consequence of the process of cooling air, several thingsoccur. One is that humidity (latent heat) is removed from the air. Thismoisture collects on the coil fins and/or anything else nearby which isbelow dew point, including the ductwork. Typically, a drain pan ispositioned below a cooling coil. The collected moisture runs down thefins and into the drain pan under the force of gravity. Water whichcollects in the drain pan flows away through a drain pipe equipped witha trap.

Another is that organic matter deposits and collects on the cooling coilfins from the air passing over them. Though the fins of the cooling coilappear to be smooth, in fact, when viewed under a microscope, they canbe seen to have an irregular and somewhat pitted surface. The organicmatter can therefore adhere easily to the damp and rough surface of thecooling coil.

Another consequence is that the cooling section is dark and at offtimes, it will be warm. Though when operating it will be quite cold, thecooling section will have varying cycles of cooling. When not cooling,the cooling coils typically reach room temperature.

Similar effects are encountered with heating coils, though typically toa lesser degree than with cooling coils.

Altogether, these consequences produce an environment in which molds andbacteria can grow and thrive. Over time, a heat exchanger can becomenear fully encrusted with microorganism activity bound to an organicsubstrate. The drain and drain pans also become a growth environment formold and bacteria. The spores and products of metabolism from both areeasily entrained into the airstream.

As this matter encrusts a heat exchanger, its heat exchange efficiencyis compromised. The efficiency reduction does not result in an energyreduction. Instead, in the case of a cooling coil, the cooling coil mustbe made to be cooler or run longer, both of which require more energyfor the same unit of work. In the case of a heating coil, the heatingcoil must be made to be hotter or run longer, both of which require moreenergy for the same unit of work. Furthermore, more energy is requiredto push air across the encrusted heat exchanger, resulting in anincreased pressure drop. Therefore, either the fan speed must beincreased, the motor horsepower increased, or both, or an oversized fanand motor are installed. Pressure drop and heat exchange efficiency candegrade up to 30% of their original values in as little as one year, onaverage 22% in three years. There is an exponential increase in energyconsumption to the linear degradation of HVAC system heat exchangeefficiency and airflow. A 30% degradation can equate to a doubling ofenergy use when these other remedial measures are used.

The conventional method of controlling the accumulation and growth ofsubstrate and microorganisms is with the use of high pressure sprayers,surfactants, acids and biocidal agents, which are applied to all growthsurfaces of the HVAC system. However, the surfactants, acids andbiocidal agents are dangerous chemicals and the distribution and use ofbiocidal agents and acids are strictly controlled by the EnvironmentalProtection Agency (EPA). In this age of workplace safety, there is worrynot only for the occupants of the building, but also for those workingon the buildings mechanical equipment. Thus, those who supply and applythese materials must use masks, gloves and gowns when handling them.These chemicals are dangerous enough that the HVAC system must be shutdown and the building vacated. As can be imagined, conventionaltreatment can be extremely expensive.

Despite the inconvenience and cost, treatment may only be effective foras little as three days to three weeks and usually not more than threemonths. Furthermore, chemical cleaning provides only a partial reductionof cooling coil pressure drop and a partial increase in heat exchangeefficiency. To make matters worse, conventional cleaning techniqueseventually damage the heat exchangers resulting in the entire heatexchanger or air handler being replaced—a very expensive event. Becauseof the problems with these chemicals, the continuous encrustation ofheat exchangers has been largely ignored.

If done properly (i.e., regularly), the cleaning of heat exchangers canbe very expensive. With cooling coils having as many as fourteen finsper inch and staggered refrigeration tubes every two inches of coildepth, cooling coils are rarely if ever cleaned completely, thereforeending in an eventual point of no return. The process is alsodestructive to the cooling coil, limiting the number of times theprocedure can be performed. Speeding up the fan requires new sheaves andbelts. Furthermore, this results in increased

$\frac{{HP}_{2}}{{HP}_{1}} = \left( \frac{{RPM}_{2}}{{RPM}_{1}} \right)^{3}$energy consumption, as brake horsepower increases to the cube of fanRPM.

Thus, increasing the fan motor size or replacing the fan and motor withlarger ones only adds to the overall energy consumption.

In order to achieve minimum IAQ levels, other modifications are used.One is to introduce extra outdoor air. However, this leads to extracooling, heating and filter costs, and may even exacerbate the heatexchanger encrustation.

Another method is to use “high efficiency particulate arrester” (HEPA)filters instead of standard particulate filters. The installation ofHEPA filters, their support assemblies and maintenance is very costly.There are also very substantial indirect costs as more power from a fanis needed to push air through the denser HEPA filters, which follows thecriteria indicated above.

The present invention arose from testing of UVC Emitters™ asmanufactured by Steril Aire U.S.A., Inc., the assignee hereof The UVCEmitters are Steril Aire's high output germicidal lamps, which arespecifically designed for cold and moving air environments such as foundin HVAC systems. In the test, UVC Emitters were installed within an airhandling system owned by Southern California Air ConditioningDistributors, Inc. (SCACD), in City of Industry, California.Specifically, UVC Emitters were installed so that their ultravioletlight output in the C band (UVC) was directed toward the cooling coil ofthe air handling system. The tests were unconcerned with energyconsumption. Rather, these tests were designed to measure improvementsto IAQ derived from eradicating mold and bacteria using the UVCEmitters.

It was clear to SCACD that the cooling coil in its air handling systemwas becoming less and less efficient, so that the air handling systemhad to consume more energy to provide its function. The cooling coil ofthe air handling system at SCACD's City of Industry facility wasapproximately twenty years old. SCACD, the worlds largest privatelyowned distributor of air conditioning equipment, had been unable toprevent cooling coil encrustation in its own facility. SCACD had triedall conventional cleaning methods, which eventually provided littlebenefit. Thus, over time, the air handling system required increasingamounts of energy to produce the same net cooling effect. It was SCACD'sexpectation that the cooling coil or system would need to be replaced inorder to obtain a reasonable flow of air of suitable temperature.

The testing of SCACD's cooling system was performed using scientific andindustry procedures under the supervision of Dr. Robert Scheir, one ofthe assignors hereof and a respected Ph.D. in Medical Microbiology.Prior to installation of the UVC Emitters, measurements were taken bySCACD of the air pressure drop across the cooling coil and the airentering and leaving dry and wet bulb temperatures. The UVC Emitterswere then installed and the cooling coil was exposed continuously to theUVC output of the UVC Emitters for four weeks. On Sep. 28, 1997, newmeasurements were taken of the air pressure drop across the cooling coiland the air entering and leaving dry and wet bulb temperatures. It wasconcluded that the heat exchange efficiency of the cooling coil hadincreased and the air pressure drop across the cooling coil haddecreased. SCACD's cooling coil appeared to have returned, as much aspossible, to an “as new” condition, something that was heretoforebelieved impossible by any method. Though the UVC Emitters were believedto have some contribution to the results of the test, SCACD officialsand the inventors remained skeptical that the UVC Emitters could havebeen exclusively responsible for the results.

It was not until several weeks later, after additional testing andanalysis, that the inventors hereof were able to confidently declarethat the UVC Emitters were responsible for the decreased air pressuredrop and increased efficiency of SCACD's cooling coil. Furthermore, fromthis work, the inventors were able to formulate and refine theparticular configuration, mathematics and specifications by which energyusage would predictably be reduced in an air handling system using UVCirradiation.

The use of germicidal lamps for air sterilization only in ductwork,though once considered potentially viable, is no longer well known tothose skilled in the art. Various reasons have contributed to the lackof success in utilizing germicidal lamps, except for limited andspecialized purposes. The functional implementation of such devices inair moving systems has been limited generally to expensive portableunits or top-of-the-wall or ceiling systems where the germicidal lamp issituated in a minimum air movement and ambient air temperature area.Germicidal lamps have sensitive physical characteristics, includingplasma gases, mercury and partial pressures thereof. When germicidallamps are used to irradiate a moving air stream, the air moving acrossthe germicidal tube lowers the tube's temperature. The mercury condensessuch that the emission of the germicidal wavelength of 253.7 nm in aconventional tube decreases as much as a 75% when the temperature fallsbelow 58° F. The phenomenon, referred to as skin effect cooling,increases the number of conventional tubes, reduces the available squarearea for airflow, reduces air changes per hour, and increases the numberof expensive tube replacements required to obtain an anticipated levelof performance.

Germicidal lamps emit ultraviolet light at the primary and secondaryemission lines of mercury (254 nm and 185 nm). At mercury's 185 nm line,ozone is created. Ozone has strict threshold limit values due to itsstrong oxidative properties and potential harm to humans. Despite theclear benefits of germicidal lamps, problems such as ozone, decreasedoutput in low temperatures and moving air and the resulting short tubelife have prevented their use in all but the most friendly ofenvironments.

For further information concerning improvements in electrical dischargedevices which are directed to overcoming such problems, reference ismade to U.S. Pat. No. 5,334,347 entitled, “Electric Discharge Device”which is co-owned with this application, and a pending application filedin the name of two of the instant inventors, Forrest B. Fencl and RobertM. Culbert, entitled “Single Ended Germicidal Lamp for HVAC Systems,”application Ser. No. 08/773,463 the disclosures of which areincorporated herein by reference. Germicidal fixtures have recentlybecome available under the Germ-O-Ray and Germitroll trademarks forinstallation in air ducts. The particular capabilities and design ofthese devices is not known to the inventors, though it is believed thatboth devices use conventional tubes having relatively short life and lowoutput.

DESCRIPTION OF THE DRAWINGS

The present invention will be described by way of exemplary embodiments,but not limitations, illustrated in the accompanying drawings in whichlike references denote similar elements.

FIG. 1 is a diagrammatic side elevational view of a part of an HVACsystem illustrating the positioning of a germicidal tube relative to aheat transfer coil and a drain pan.

FIG. 2 is a diagrammatic isometric elevational view of a horizontal flowflat heat transfer coil to illustrate the positioning of germicidaltubes relative of the coil's heat transfer fins.

FIG. 3 is a diagrammatic elevational illustration of a portion of thecross section of the horizontal flow flat heat transfer coil illustratedin FIG. 2 to better illustrate the manner in which the germicidal tubeis positioned adjacent to the coil and drain pan—perpendicular to theparallel planes of the coil and illustrating the manner in which UVirradiation is applied thereto.

FIG. 4 is a diagrammatic side elevational representation of a germicidalfixture and tube taken in a plane perpendicular to the longitudinal axisof the germicidal tube and fixture to illustrate radiation emitted fromthe germicidal tube when in that plane.

FIG. 5 is a diagrammatic planar representation of UV radiation emittedfrom the germicidal tube illustrated in FIG. 4 taken in a plane parallelto the longitudinal axis of the lamp and perpendicular to parallelplanes of the heat transfer fins to illustrate the directing andreflecting of UV irradiation from all points of the lamp in that planewhen applied between adjacent vertical planes of the heat transfer fins,and the manner in which a particular point on the tube will radiatephotons in the direction of the fins and reflecting off the fins toincrease flux density and dosage applied thereto.

FIG. 6 is a diagrammatic planar representation as in FIG. 5 illustratingthe manner in which the UV radiation from all points of the germicidaltube in that plane will be applied between each pair of adjacentparallel planes of the fins, and the manner in which the radiation froma particular point on the germicidal tube will be received and reflectedbetween all of the parallel fins of the coil's tubes for a betterunderstanding of how the radiated energy and subsequent irradiance ofthat energy is accumulated and thus enhanced.

FIG. 7 is a diagrammatic illustration of the cross section of aresidential “A” coil to illustrate positioning of a germicidal tubeperpendicular to the coil's fins in accordance with one aspect of theinvention.

FIG. 8 is another diagrammatic perspective elevational view of ahorizontal flow flat heat transfer coil to illustrate the positioning ofgermicidal tubes at right angles to the coil's heat transfer fins.

FIG. 9 is another diagrammatic perspective elevational view of ahorizontal flow flat heat transfer coil to illustrate the positioning ofgermicidal tubes parallel to the coil's heat transfer fins.

FIG. 10 is a graph of the air entering and leaving dry bulb temperatureover several weeks during testing of germicidal lamps at SCACD.

FIG. 11 is a graph of the air entering and leaving wet bulb temperatureover several weeks during testing of germicidal lamps at SCACD.

FIG. 12 is a graph of decrease in pressure drop over several weeksduring testing of germicidal lamps at SCACD.

FIG. 13 is a graph of the increase in system CFM over several weeksduring testing of germicidal lamps at SCACD.

FIG. 14 is a planar top view of the residential “A” coil showing thegermicidal tubes as perpendicular to the plane of the coil's fins.

FIG. 15 is a diagrammatic illustration of the cross section of an “M”coil to illustrate positioning of a germicidal tube at right anglesrelative to the coil's fins in accordance with one aspect of theinvention.

FIG. 16 is a diagrammatic illustration of the cross section of a singlecoil to illustrate positioning of a germicidal fixture relative to thecoil in accordance with one aspect of the invention.

FIG. 17 is a diagrammatic illustration of the cross section of an “N”coil to illustrate positioning of a germicidal tube relative to the coilin accordance with one aspect of the invention.

FIG. 18 is a diagrammatic illustration of the cross section of a complexcoil arrangement to illustrate positioning of a germicidal tube relativeto the coil in accordance with one aspect of the invention.

These and additional embodiments of the invention may now be betterunderstood by turning to the following detailed description wherein anillustrated embodiment is described.

DETAILED DESCRIPTION OF THE INVENTION

Throughout this description, the embodiments and examples shown shouldbe considered as exemplars, rather than limitations on the apparatus andmethods of the present invention.

Referring now to FIG. 1, there is shown an air duct or plenum 100 of anHVAC system, through which air is discharged in accordance with theoperation of a suitable blower or fan 120. A number of germicidal lamps110 are mounted in a chamber 105 of the air duct 100. The germicidallamps 110 include a germicidal tube 111 coupled to and carried by a base112. For the germicidal lamps to operate effectively in the harshenvirons of an air duct, it is preferred that germicidal lampsspecifically designed for such environments be employed. In particular,the germicidal lamps sold by the assignee of this invention, Steril-AirU.S.A., Inc, and sold under the trademark, “UVC Emifter,” are preferred.The base 112 contains electrical circuitry and ballast for energizingthe germicidal tube 111 to emit ultraviolet radiation, preferably in the“C” band (UVC). Although not shown in FIG. 1, there may be a number ofsingle-ended germicidal tubes coupled to a single base as shown in FIGS.14-18, with the base mounted on the outside of the duct 100. Such aconfiguration is disclosed in the co-pending application referred toabove, “Single-Ended Germicidal Lamp for HVAC Systems.” Otherconfigurations of germicidal tubes and bases are within the scope of theinvention.

A horizontal flow, flat heat transfer coil 130 and drain pan 140 of theHVAC system are positioned within the chamber 105, preferably upstreamfrom the germicidal lamp 110 with reference to the air flow. While thisis the preferred positioning, it is to be understood that the lamp 110may also be positioned upstream from the coil 130 and drain pan 140,whichever provides good uniform radiation coverage of the coil 130 anddrain pan 140 and best accommodates the HVAC system's layout.

The coil 130, which is well known in the art, comprises circuited tubes131 through which refrigerant circulates and a number of substantiallyflat, planar parallel fins 135 attached at generally regular spaces onthe tubes 131. The relationship between the coil tubes 131 and the fins135 can be better appreciated from FIG. 3. The fins 135 increase theeffective surface area of the tubes 135 to thereby increase heattransfer from the air to the surface of the coil 130. Because of theexcellent heat transfer properties, low expense and ease of manufactureof aluminum, a typical coil is substantially constructed of thismaterial. In general, for heat transfer, cost and manufacturing reasons,the fins 135 are rarely coated. Coincidently, aluminum has in excess of60% reflectivity for the primary UV emission line, a wavelength of 253.7nm. However, the method of the invention is also applicable to fins ofother materials which are relatively good reflectors of UV's primaryemission line.

Further upstream from the coil 130 may be a number of filters 150.

Referring now to FIG. 2, there is shown a diagrammatic perspective viewof the fins 135 and the germicidal lamps 110. For a given fin 135 a,there is defined a plane 136 a of the fin 135 a. For a given germicidaltube 111 a, there is defined a longitudinal axis 113 a. Preferably, thelongitudinal axis 113 a of the germicidal tube 111 a is at a right angleto the plane 136 a of the fins 135 a. Since the fins 135 are paralleland vertical, the germicidal tubes 111 will be at right angles andhorizontal to the plane of all of the fins 135.

Referring now to FIG. 3, it can be seen that at least one germicidaltube 111 is also positioned so as to irradiate at least part of thedrain pan 140 directly. In accordance with the invention, the coil'stubes 131 and fins 135 reflect UV radiation from the germicidal tube111. The fins 135 also reflect UV radiation on into the drain pan 140.Accordingly, the surface of the drain pain 140 will also be irradiatedthrough reflections of the UV radiation from the tubes 131.

In determining the spatial relationship between the germicidal tubes 111and the coil 130 (FIG. 1), the objective is to obtain a uniformdistribution of UV radiation across the coil's face 130 a. (The coil'sface 130 a also substantially defines the leading edge of the coil'sfins 135.) It has been determined that, for a germicidal tube which ispositioned in accordance with the invention, the spatial distribution ofUV radiation follows precisely that of a diffuse area source and,surprisingly, not an isotropic point source. The pattern of UV radiationfrom a germicidal lamp is shown in FIG. 4. It can be seen that althoughthe germicidal tube 111 is a source of radiation, the base 112 iseffectively a secondary (reflected) source of UV radiation. The diffuseradiation of the germicidal tubes 111 and diffuse reflection istherefore defined as a near field effect, not as an inverse square law.This finding is contrary to normal expectations, and therefore placementof germicidal tubes in accordance with the present invention results inthe need for fewer germicidal tubes. Put another way, when thegermicidal tubes 111 are positioned in sufficient proximity to the coil130, the intensity of UV radiation from the germicidal tubes 111striking the coil 130 is, to a degree, independent of the distance ofthe germicidal tubes 111 from the coil 130.

In one embodiment of the invention, germicidal tubes, spaced 24 inchesapart, were positioned at right angles to the plane of the fins andabout twelve inches from the drain pan and twenty inches from the faceof the coil. It has been found that positioning the germicidal tubes 11120 inches from the leading edge 130 a of the fins 135, in conjunctionwith appropriate germicidal tube-to-tube spacing, is particularlyeffective in inhibiting the growth of microorganisms on all surfaces ofthe coil 130 and in all surface areas of the drain pan 140.

As shown in FIG. 4 the photons emitted from a particular point on thegermicidal tube 111 radiate in all directions. Because FIG. 4 is anelevational view, the global radiation of these photons is not shown.These photons would, however, also radiate outwardly and inwardly fromthe plane of the paper upon which the planar representation isillustrated and from all surfaces of the tube 111. In addition, toincrease the photons applied to the coil and drain pan, a germicidallamp with a reflector (preferably incorporated in the base 112) isutilized. Those photons emitted and reflected in a plane parallel to theplanes of the fins 135 penetrate into the coil 130 and are reflected bythe internal coil structure (i.e., the tube 131 and the fins 135).

As illustrated in FIGS. 5 and 6, because of the global emission ofphotons from the germicidal tube 111, photons emitted from all points onthe germicidal tube 111 and reflected from the base 112, other thanthose emitted in a plane parallel to the planes of the fins 135 strikethe fins 135 adjacent to their leading edge 130 a (the edge closest tothe germicidal tube 111) are reflected between the spaced parallel fins135 in accordance to the angle of incidence that the photon takes. Thefins 135 and circuited tubes 131 therefore reflect photons amongst oneanother such that the photons are applied throughout the coil 130 andthe drain pan 140. Because the global emission occurs from all pointsalong the longitudinal axis 113 a of the germicidal tube 111, the fluxdensity and uniformity of incidence to the fins 135, the circuited tube131 and the drain pan 140 increases in the manner diagrammaticallyillustrated by the reflectivity shown occurring between a pair of fins135 in each of these Figures. Such increased flux density and dosageoccurs between all of the spaced parallel fins 135 and drain pan 140 inthis manner. However, for purposes of illustration, such increases areshown in FIG. 5 occurring between only two adjacent fins.

As can be seen from these Figures, complete and uniform irradiation isachieved. Preferably, the number and position of germicidal tubes isselected so that the UV radiation is uniformly distributed across thecoil 130 and drain pan 140.

Referring now to FIG. 7, there is shown a diagrammatic illustration ofthe cross section of a vertical flow “A type” heat transfer coil 740 toillustrate positioning of germicidal tubes 711 a, 711 b perpendicular tothe coil's fins in accordance with one aspect of the invention. Thegermicidal tubes 711 a, 711 b, in base 712, are positioned at rightangles to the planes in which the fins 735 lie. The germicidal tubes 711a, 711 b will also partially directly irradiate the drain pans 740 a,740 b, while the coil 730 will cause direct and indirect (reflected)irradiation of the drain pans 740 a, 740 b in the manner describedabove. FIG. 14 is a partial top view of the A coil and germicidal tubeof FIG. 7.

It has been determined that positioning the germicidal tubes such thattheir longitudinal axes are perpendicular to the parallel planes inwhich the fins extend causes the emitted UV radiation to be applieddirectly and indirectly to the heat transfer coil and surrounding areasin the path of emission and reflection, and on into the drain pan. Theactual positioning of the germicidal tubes, and the number of germicidaltubes to be employed in order to attain these objectives, is determinedbased on the goal that the UV radiation is uniformly distributed acrossthe coil and drain pan.

Because the UV radiation strikes the fins and circuited tubes at allincident angles, they continuously reflect and effectively direct the UVradiation within and throughout the coil. This continuous reflection anddirection of the UV radiation increases the flux density of the photonsapplied to the coil, the drain pan and continues in the airstream untilabsorbed. The increased number (flux density) of incident photons alsoassures that organisms in the airstream are struck from all angles.Also, the increased distance of photon travel, and thus available timeof exposure, provides for a potentially greater dosage (intensitymultiplied by time) to be received by any surface or airbornemicroorganism. In this manner the coil, drain pan and surrounding areaare completely exposed to the UV radiation sufficiently to eradicatesurface and substantially reduce airborne microorganisms.

Our continued research into the positioning and aiming of germicidallamps and into various target environments for germicidal lamps hasenhanced our understanding of them. For example, we have learned thatthe greatest “time weighted” amount of nutrient and moisture is in thecooling coil and not the drain pan. Because of this, the most activeregion of microbial activity (number) in an air conditioning system isin the cooling coil and during and after the cooling cycle. Thisconflicts with our initial deduction that the drain pan, when the airconditioner is not running, is the most active region.

As we focused on the cooling coil, we learned that in order to provide acomplete kill throughout the cooling coil, a uniform distribution ofgermicidal UVC energy must be provided. This conflicts with our initialdeduction that there must be a uniform amount of energy throughout thecooling coil. This difference resulted in the inventions claimed in ourU.S. Pat. No. 5,817,276. In order to exploit the need for uniformdistribution of energy, we have focused on positioning our UVC Emittersto maximize distribution of energy across a heat exchanger andthroughout a heat transfer coil by reflection within the heat transfercoil. Our research has shown that while a higher output germicidal lampis important, unexpectedly good results are achieved by aiming andreflecting the UVC radiation to maximize uniform distribution(irradiation).

Our initial focus was on IAQ. Thus, we expected that the best locationfor a germicidal lamp is downstream of a cooling coil, working from thehighest degree of microbial activity to the lowest. As discussed above,to maximize uniform distribution of the UVC energy, the plane of thetube should be at a right angle to the conforming lines of the coolingcoil's fins. Through initial radiation and incident reflection—totalirradiation—UVC energy bathes all surfaces of the cooling coil and drainpan as well as the line-of-sight airstream.

In order to provide a uniform distribution of photon energy through thedeepest part of a heat transfer coil, depending on its height and width,we prefer having several tubes at selected “tube to tube” distances andat selected “tube to coil” distances. The minimum photon energy strikingthe leading edge of all heat transfer coil fins is preferably 716 μW/cm²at the closest point and through placement, not less than 60% of thatvalue at the farthest point. This therefore sets the minimum number oftubes, their center lines and their distance from the air-leaving orair-entering surface of the heat transfer coil. If positioned in thismanner, nearly equal amounts of energy will also strike the drain pan inmost cooling systems, either directly or indirectly. The particularposition of a germicidal lamp relative to a heat transfer coil dependson the capabilities and characteristics of the germicidal lamp used.

Microbial samplings of several experimental sites showed a uniform killof all microbial activity throughout the tested cooling coils. Thekilling of mold and bacteria on the cooling coils also reduced oreliminated microorganisms and their products from the airstream withreduction of the following products in the relevant occupied spaces:

-   -   Airborne primary solvents and volatile organic compounds.    -   Microorganism metabolic gas exchange, raising airborne CO₂, etc.    -   Spore production which causes forms of Sick Building Syndrome        (SBS).    -   Particle toxins which can cause both SBS and Building Related        Illness (BRI).    -   Other bioaerosol related IAQ problems such as allergy, asthma,        and symptoms such as headache, burning eyes and fatigue.

Another important discovery from our recent research is thatmicroorganism nutrients are primarily organic in nature. As these minuteorganic substances impinge on the surfaces of a heat exchanger, bothmold and bacteria bind-up this material to the surface of the heatexchanger during their growth and division process to hold moisture andmaintain activity. This results in the dingy, dirty appearance whichheat exchangers obtain over time.

Our research has shown that the ionizing radiation from our UVC Emittersis a key element in the killing and degradation process ofmicroorganisms in cooling and heating systems. An ion is a particleformed when a neutral atom or group of atoms gains or loses one or moreelectrons. An atom that loses an electron forms a positively chargedion, called a cation and an atom that gains an electron forms anegatively charged ion, called an anion. Our scientific testing hasestablished that the dead microorganisms then further undergo damagethrough this free radical process. Absorption of UVC energy leads to theformation of radical cations, anions and electrons, and electronicallyexcited molecules. One reason is that about 70% of the energy isabsorbed by the available moisture and about 30% by organic matter andother solutes. Water absorption of UVC leads to the formation ofoxygen/hydrogen radicals or hydroxyls, solvated electrons and hydrogenatoms which are all very safe to humans and the environment. Thisprocess is similar to that produced by outdoor sunshine. In theseprocesses, the atoms are separated, thus disassociating individual wholemolecules to produce individual radicals to the original structure.These water-derived radicals are all highly reactive and atomicallydegrade (vaporize) organic material.

Only after continued study did we learn that the degradation processcontinues on the dead microorganisms as well as any residual organicnutrients. In time, the heat transfer coil and drain pan becomeorganically clean. We have observed this effect on severely encrustedcooling coils in as little as four weeks of continuous operation. Theresults from the UVC energy degrading the organic matter are:

-   -   Heat exchanger pressure drop goes back to “as new.”    -   Heat exchanger airflow goes back to “as built” or “as        installed.”    -   Heat exchanger cleanliness goes back to “as built” or “as        installed.”    -   Heat exchanger capacity goes back to “as built” or “as        installed.”    -   Heat exchanger cleaning is no longer required.    -   Space humidity and temperature are more easily controlled.    -   Heat exchangers no longer seed the ductwork or space with        bioaerosols.

The elimination of organic material from the heat exchanger as shownabove has other significant advantages for the user from an energystandpoint. The reduction in pressure drop across the heat exchangerequates to a reduction in air horsepower and is expressed by thefollowing formula:

${Hp} = \frac{{CFM}*5.2*\Delta\;{PD}}{33000\;\eta}$Where:

-   -   Hp=horsepower    -   CFM=cubic feet per minute    -   5.2=conversion of inches WG to psi    -   ΔPD=change in pressure drop across the heat exchanger    -   33000=conversion of foot pounds to horsepower    -   η=system efficiency

FIGS. 10, 11, 12 and 13 show graphs of “before” and “after” conditionsat our test site at SCACD, discussed above. FIG. 10 shows the airentering dry bulb temperature and air leaving dry bulb temperature overa one month period. We found a 3.7° greater temperature differentialafter installation of the UVC Emitters. FIG. 11 shows measured coolingcoil pressure drop over the same one month period. We found a 28% lowerpressure drop across the cooling coil after installation of the UVCEmitters. FIG. 12 shows the air entering wet bulb temperature and airleaving wet bulb temperature over the one month period. We found a 1.8°greater temperature differential after installation of the UVC Emitters.FIG. 13 shows measured system air flow over the one month period. Wefound an 8.6% increase in system CFM after installation of the UVCEmitters.

Applying the reduction in pressure drop shown results in horsepowersavings of 0.58 and when taken against the operating hours and the costper kW, energy savings of approximately $163 per year are realized.However, the big savings are in heat transfer as shown in the EnteringAir Temperature (EAT) and Leaving Air Temperature (LAT) of both the WetBulb (FIG. 12) and Dry Bulb (FIG. 10). The resulting change in totalheat exchanger capacity is expressed as:Total Heat=4.5×CFM×(h ₁ −h ₂)

-   -   Where:    -   4.5=conversion of pounds of air to 1 CFM    -   CFM=cubic feet per minute    -   h₁=temperature of air entering wet bulb    -   h₂=temperature of air leaving wet bulb

Applying the reduction in wet bulb LAT against the above formula,operating hours and cost per kW, energy savings of approximately $11,724per year are realized. The impact nationwide of using UVC in this mannerwould be dramatic to say the least.

When germicidal tubes are utilized as described herein, total fluxdensity between each of the fins of a heat transfer coil is at itshighest. As such, microorganisms that are not defused to the heatexchanger's surface and killed are mostly killed in the air due to theincreased flux density from the resulting irradiation and lack ofshadows. This reduces (kills) airborne microorganisms by as much as 90%on a single pass, reducing the incidence of airborne transmittedinfections including such diseases as measles, chicken pox, whoopingcough, common colds, influenza and tuberculosis.

Our research shows that UVC energy at 253.7 nm ionizes the organic bonds(as described above) of the typical materials deposited on heatexchangers. UVC energy vaporizes these materials at the solid, molecularand atomic level. The process time averages about three weeks ofcontinuous exposure to complete and then maintains the cleanliness of aheat exchanger for the life of the system. This in turn returns airflowto “as designed” values. The process has been confirmed repeatedly.

The process of cleaning the heat exchanger somewhat differs from theprocess of controlling the presence of surface and airbornemicroorganisms. The goal in cleaning the heat exchanger is to eliminateorganic matter from all surfaces of the heat exchanger. In contrast, thegoal in controlling the presence of surface and airborne microorganismsis to sufficiently kill just those microorganisms which are likely toaffect IAQ. Thus, to maximize energy savings by eliminating organicmatter on a heat exchanger, it may be necessary to locate germicidallamps upstream from the heat exchanger as shown in FIG. 8.

Heat transfer coils are typically constructed of aluminum. Aluminum canreflect the 253.7 nm wavelength of UVC at up to 83%. Under a microscopeand to the quarter micron wavelength of UVC energy, a heat exchanger'saluminum surface shows imperfections that look like peaks, valleys, pitsand rocks. Installing our UVC Emitters at right angles to the plane of aheat transfer coil's fins results in the entire heat transfer coilsurface receiving radiation through direct and/or incident anglereflection.

In accordance with the invention, UVC energy at 253.7 nm is utilized tovaporize accumulated debris reducing pressure drop and increasing heatexchange efficiency to “as new.” The UVC light can be utilized upstreamor downstream of the heat exchanger, whichever facilitates air handlerdesign. Preferably, as described above, a tube's longitude is at rightangles to the plane of a coil's fins. Preferably, tubes are positionedon center lines and distances from the top and bottom of the heattransfer coil to provide a uniform distribution of energy sufficient toclean the entire heat transfer coil surface through direct and reflectedUVC energy.

The tubes of our UVC Emitters are preferably positioned from the heatexchanger surface at a distance which is equal to 80% of the distance ofthe light string centerline. For example, if the centerlines were 24″,then the distance from the coil should be approximately 20″. Preferably,the fixtures include a reflector to concentrate the energy produced, andthe reflector is aimed toward the heat exchanger.

Once installed, the germicidal lamps are preferably run 24 hours per dayuntil the heat exchanger is completely cleaned. Once the heat exchangeris cleaned, the germicidal lamps may be run intermittently as requiredto maintain the cleanliness and pressure drop of the heat exchanger.

For new heat transfer coils, germicidal lamps may be installed on thesame plane as the plane of the fins, as shown in FIG. 9. The reason isthat when the coil is new, the only requirement is to maintain it in the“as new” condition. This will save significant energy over the life ofthe system. While the amount of UVC energy reaching all surfaces of theheat transfer coil is less than in the preferred right angle position,calculations can be made that provide a degradation rate equal to thedeposition rate of debris. This will keep the heat transfer coil cleanindefinitely, which is the most affordable way to minimize energy use inexchanging heat or flowing air. These savings are shown in the formulasset forth above.

FIGS. 15-18 show various installations of germicidal lamps with respectto a variety of heat exchanger types. The installations of FIGS. 15-18were achieved by considering both the desirability of reducing energyconsumption, cost of installing a germicidal lamp (including the cost ofthe lamp itself), and structural limitations of the heat exchanger andits environs. FIG. 15 shows an “M” coil 1510, a dual-tube germicidallamp 1520 including single-ended tubes 1521, 1522, insulated duct walls1530 and drain pans 1540. FIG. 16 shows a slab coil heat exchanger 1610,a germicidal lamp 1620 including single-ended tube 1621, insulated ductwalls 1630 and a drain pan 1640. FIG. 17 shows an “N” coil 1710, agermicidal lamp 1720 including single-ended tube 1721, insulated ductwalls 1730 and a drain pan 1740. FIG. 18 shows a complex coil 1810, agermicidal lamp 1820 including single-ended tubes 1821, 1822, insulatedduct walls 1830 and drain pans 1840.

Properly designed HVAC-type germicidal devices, such as our UVCEmitters, can be installed without interruption of the normal operationof an HVAC system. Because of the proven energy-saving abilities ofgermicidal lamps, other more expensive and less beneficial energy-savingdevices may not be needed.

Once the germicidal lamps are installed and turned on:

-   -   Coil contaminants are ionized and degraded (vaporized).    -   The germicidal lamps clean the coil to “as new” specifications,        completely returning heat exchange efficiency (heat removal) and        pressure drop (airflow) to original values.    -   The germicidal lamps keep the heat exchanger in this condition        for the life of the system.    -   The process is not destructive to the heat exchanger's surface        or any other inorganic material.    -   The process requires no hazardous chemicals.    -   The process is environmentally friendly, as it adds nothing to        the air or drainage system.    -   The germicidal lamps do the job continuously without shutting        down the system or vacating the building.    -   A complete installation of germicidal lamps can cost less than a        properly performed heat transfer coil cleaning.

Although exemplary embodiments of the present invention have been shownand described, it will be apparent to those having ordinary skill in theart that a number of changes, modifications, or alterations to theinvention as described herein may be made, none of which depart from thespirit of the present invention. All such changes, modifications andalterations should therefore be seen as within the scope of the presentinvention.

1. A method of controlling the presence of surface and airbornemicroorganisms in an air handler having a heat transfer coil comprisinga tube and a plurality of spaced parallel fins and defining a surface,comprising intermittently energizing a germicidal lamp to emitdistributed UVC radiation wherein the germicidal lamp is energizedduring and after a cooling cycle of the air handler until the surface isorganically clean positioning the germicidal lamp in proximity to theheat transfer coil, wherein the intensity of the UVC radiation strikingthe heat transfer coil is, to a degree, independent of the distance ofthe germicidal lamp to the heat transfer coil directing the UVCradiation across the coil face to the coil's tube and fins reflectingand directing the ultraviolet radiation by the coil's tube and thefins-throughout the coil, thereby increasing the flux density of theultraviolet radiation and the dosage of the radiation applied toairborne microorganisms and microorganisms carried on the surface. 2.The method of controlling the presence of surface and airbornemicroorganisms in an air handler of claim 1 wherein said reflecting anddirecting of the ultraviolet radiation received by the coil and the finsis affected by the reflectivity of ultraviolet radiation from thematerials from which the fins are fabricated, thereby increasing theflux density of said radiation.
 3. The method of controlling thepresence of surface and airborne microorganisms in an air handler ofclaim 1 wherein said reflecting and directing of the ultravioletradiation reflected from the fins continues until said radiation isabsorbed, thereby increasing the dosage of radiation applied.
 4. Themethod of controlling the presence of surface and airbornemicroorganisms in an air handler of claim 1 wherein the germicidal tubeemits ultraviolet radiation substantially at 253.7 nm and generates aninsignificant quantity or less of ozone.
 5. The method of controllingthe presence of surface and airborne microorganisms in an air handler ofclaim 1 wherein the surface is disposed in an environment having atemperature below 58° F.
 6. The method of controlling the presence ofsurface and airborne microorganisms in an air handler of claim 1,wherein killing of microorganisms carried on the surface with the UVCradiation reduces the concentrations of airborne volatile organiccompounds produced by the microorganisms carried on the surface.
 7. Amethod of maintaining cleanliness of a heat transfer system in an airhandling system through UVC irradiation, wherein during operation of theair handling system, organic matter accumulates upon an internal surfaceof the heat transfer system, the accumulated organic matter therebydegrading the performance of the heat transfer system, the methodcomprising intermittently energizing a germicidal lamp to emitdistributed UVC radiation wherein the germicidal lamp is eneraizedduring and after a cooling cycle of the air handling system until theinternal surface of the heat transfer system is organically cleanpositioning the germicidal lamp in proximity to the internal surface,wherein the intensity of the UVC radiation striking the internal surfaceis, to a degree, independent of the distance of the germicidal lamp tothe internal surface directing the UVC radiation at the internal surfaceof the heat transfer system.
 8. The method of maintaining cleanliness ofa heat transfer system in an air handling system through UVC irradiationof claim 7, the heat transfer system comprising a heat exchanger, themethod further comprising reflecting and directing the UV radiation bythe heat exchanger, thereby increasing the distribution and flux densityof the UV radiation and the dosage of the radiation applied to theaccumulated organic matter.
 9. The method of maintaining cleanliness ofa heat transfer system in an air handling system through UVC irradiationof claim 7 wherein the reflecting and directing of the UV radiationreceived by the heat exchanger is effected by the reflectivity of UVradiation from the materials from which the heat exchanger isfabricated, thereby increasing the flux density of the radiation. 10.The method of maintaining cleanliness of a heat transfer system in anair handling system through UVC irradiation of claim 7 wherein the airhandling system comprises a cooling system.
 11. The method ofmaintaining cleanliness of a heat transfer system in an air handlingsystem through UVC irradiation of claim 7 wherein the directing of theUVC radiation received by the surface of the heat transfer system iseffected by the reflectivity of ultraviolet radiation from the materialsfrom which the heat transfer system is fabricated, thereby increasingthe flux density of the radiation.
 12. The method of maintainingcleanliness of a heat transfer system in an air handling system throughUVC irradiation of claim 7 wherein the surface of the heat transfersystem is disposed in an environment having a temperature below 58° F.13. A method of maintaining cleanliness of a drain pan of a heattransfer system through UVC irradiation, wherein during normal useorganic matter accumulates upon a surface of the drain pan, theaccumulated organic matter thereby degrading the performance of thedrain pan, the method comprising intermittently energizing a germicidallamp to emit distributed UVC radiation wherein the germicidal lamp isenergized during and after a cooling cycle of the heat transfer systemuntil the surface of the drain van is organically clean positioning thegermicidal lamp in proximity to the drain pan, wherein the intensity ofthe UVC radiation striking the drain pan is, to a degree, independent ofthe distance of the germicidal lamp to the drain pan directing the UVCradiation at the drain pan.
 14. The method of maintaining cleanliness ofa drain pan through UVC irradiation of claim 13 wherein the directing ofthe UVC radiation received by the drain pan is effected by thereflectivity of ultraviolet radiation from the materials from which thedrain pan is fabricated, thereby increasing the flux density of theradiation.
 15. The method of maintaining cleanliness of a drain panthrough UVC irradiation of claim 13, wherein the germicidal lamp emitsultraviolet radiation substantially at 253.7 nm and generates aninsignificant quantity or less of ozone.
 16. The method of maintainingcleanliness of a drain pan through UVC irradiation of claim 13 whereinthe surface of the drain pan is disposed in an environment having atemperature below 58° F.
 17. A method of maintaining cleanliness anapparatus through UVC irradiation, wherein during normal use organicmatter accumulates upon a surface of the apparatus, the methodcomprising providing a germicidal lamp positioning the germicidal inproximity to the apparatus, wherein the intensity of the UVC radiationstriking the apparatus is, to a degree, independent of the distance ofthe germicidal lamp to the apparatus intermittently energizing thegermicidal lamp to emit substantially UVC radiation wherein thegermicidal lamp is energized during and after a cooling cycle of theapparatus until the surface is substantially clean of the accumulatedorganic matter directing the UVC radiation at the surface to affectingcleaning of the accumulated organic matter on the surface of theapparatus.
 18. The method of maintaining cleanliness of a surfacethrough UVC irradiation of claim 17 wherein the directing of the UVCradiation is effected by the reflectivity of ultraviolet radiation fromthe materials from which the surface is fabricated, thereby increasingthe flux density of the radiation.
 19. The method of maintainingcleanliness of a surface through UVC irradiation of claim 17 wherein thegermicidal lamp emits ultraviolet radiation substantially at 253.7 nmand generates an insignificant quantity or less of ozone.
 20. The methodof maintaining cleanliness of a surface through UVC irradiation of claim17 wherein the surface of the apparatus is disposed in an environmenthaving a temperature below 58° F.
 21. The method of maintainingcleanliness of a surface through UVC irradiation of claim 17 furthercomprising exposing the surface to cold, moving air.
 22. The method ofcontrolling the presence of surface and airborne microorganisms in anair handler of claim 1, wherein at least 716 μW/cm^2 of UVC radiation isstriking a leading edge of the fins and a magnitude of least 60% of theat least 716 μW/cm^2 of UVC radiation is striking a farthest point ofthe heat transfer coil from the leading edge.